Bar material automatic labeling method and the system thereof

Abstract

An automatic material labeling method includes the following steps: (a) a positioning module detects at least one material entering the detection range; (b) the positioning module performs positioning detection on the labeling surface of the material and transmits the detection result to a central control system for analysis; (c) the central control system controls a motion module to drive a cleaning module to clean the labeling surface based on the positioning detection result; and (d) the central control system controls a motion module to drive a spray gun of a labeling module to label the labeling surface based on the positioning detection result.

Description

[Technical Field]

[0001] This disclosure relates to the field of material production technology, and more particularly to a method for automatically labeling data on the end face of a material and a system for performing this method. [Previous Technology]

[0002] Steel billets are a widely used commodity in the steel industry. Their manufacturing process involves several key steps to ensure that the product meets specific specifications and quality standards. Due to the wide variety of steel billet types and the difficulty in identifying products with different carbon ratios and manufacturing processes, they need to be marked with paint after hot processing to facilitate subsequent process inquiries.

[0003] The initially purchased steel raw materials (usually carbon steel bars) need to be heated to improve their plasticity after being cut and fed into the processing machine. Typically, the steel needs to be heated to at least 1000 degrees Celsius to become softer and easier to process. The heated steel is then fed into processing machines such as hot rolling mills or stretching machines, where it is rolled and stretched by rollers or dies to form steel billets of a specified shape and size. As mentioned above, due to the extremely high temperatures involved in hot forming operations, with ambient temperatures reaching 85-100 degrees Celsius, this poses a very high risk to workers.

[0004] After hot forming, the steel billet is marked with information such as model number, size specifications, and carbon content to facilitate subsequent processes in accessing information about the billet. Since the steel billet is still hot-formed, it must be cooled to a suitable temperature before marking.

[0005] Regarding the cooling process, the current practice is for workers to use large machinery to transport the high-temperature steel billets to a designated location for cooling. After the temperature drops slightly, the billets are continuously sprayed with powerful water jets to further reduce their temperature. This process not only consumes a lot of labor and time, but also makes the steel billets prone to deformation during transportation.

[0006] However, even after the above cooling steps, the temperature of the steel billet is still as high as 400 to 600 degrees Celsius. After the workers spray the paint used for marking onto the surface of the steel billet, the paint is very easy to peel off, making it difficult to identify. Workers exposed to the high-temperature risk in the work environment are also prone to marking errors.

[0007] In addition, after steel is hot-processed into steel billets, it comes into contact with cold air, which makes it very easy for rust to appear on the surface of the steel billet. If the rust is not removed, the workers will mark the surface of the rust on the steel billet. As the billet is transported in the later stages of the process, the rust will peel off, making it impossible to identify the markings.

[0008] In addition, the viscosity of the paint used for marking will also affect the adhesion of the marking. Low-concentration paint is not suitable for adhering to high-temperature steel blanks, while high-concentration paint not only increases costs but also requires continuous stirring, otherwise it is easy to solidify and cause nozzle blockage, which takes time to clean the nozzle and causes process delays.

[0009] The main problems in the current steel billet manufacturing process include: the hot-processed steel billet temperature is too high for operation; multiple processes are required to partially cool the steel billet before printing and marking can be performed; rust peeling makes it difficult to identify the markings; low-concentration paint is not suitable for adhering to high-temperature steel billets; additional manpower is required for printing and to use large machinery to handle the steel billets; the steel billets are severely deformed due to thermal expansion and contraction during transportation after hot processing, and it is impossible to record or transmit steel billet production information in a timely manner.

[0010] Accordingly, how to develop an "automatic material labeling method" that can improve the shortcomings of conventional inkjet printing labeling of steel billet end faces, such as labeling failure, labor costs, and process costs, is an issue that people in related technical fields urgently need to solve. [Summary of the Invention]

[0011] In one embodiment, this disclosure proposes an automatic material labeling method, which includes the following steps: (a) a positioning module detects at least one material entering the detection range; (b) the positioning module performs positioning detection on the labeling surface of the material and transmits the detection result to a central control system for analysis; (c) the central control system controls a motion module to drive a cleaning module to clean the labeling surface according to the detection result; and (d) the central control system controls the motion module to drive the spray gun of a labeling module to label the labeling surface according to the detection result.

[0012] In addition, this disclosure also proposes a system for storing and executing the material automatic labeling method as described above.

Implementation Method

[0014] Please refer to Figure 1. The flow 200 of the automatic material labeling method disclosed herein is suitable for being built into a software program and stored in the storage of a computer. When the processor of this computer reads the software program, it will execute the following steps 202 to 208. Please also refer to Figures 1 to 4 to illustrate the steps of the flow 200 of the automatic material labeling method.

[0015] It is worth noting that the materials mentioned in this disclosure, such as steel billets and steel strips, are still at a relatively high temperature after being hot-processed and formed, making them unsuitable for manual labeling. Therefore, the automatic labeling method for materials provided in this disclosure can be used to perform fully automated labeling of high-temperature materials, avoiding harm to on-site workers and improving the accuracy of the operation.

[0016] Please refer to Figures 1 to 3. In step 202, a positioning module 10 detects that most of the materials 20A to 20F are transported into the detection range 11.

[0017] As shown in Figure 2, materials 20A~20F are conveyed into the detection range 11 by a conveyor belt 70 and then stop moving.

[0018] As shown in Figures 2 and 3, the positioning module 10 may be, for example, a 3D vision camera with image transmission capabilities. The positioning module 10 is electrically connected to the central control system 30. The operation of the positioning module 10 can be controlled by the central control system 30; the central control system 30 may be, for example, a computer with internal storage and a processor.

[0019] As shown in Figure 3, when no material is detected within the detection range 11, an alarm system 12 can be triggered to issue an abnormal alarm. The alarm system 12 can be electrically connected to the positioning module 10 and the central control system 30. The central control system 30 controls the alarm system 12 to issue an alarm in an audible and visual manner.

[0020] As shown in Figure 3, the positioning module 10 can be placed in a housing 13. The housing 13 is connected to a cooling positive pressure system 14 to maintain a set temperature and positive pressure inside the housing 13, so as to protect the positioning module 10 from high temperature damage and dust pollution in the working environment.

[0021] The cooling positive pressure system 14 can, for example, introduce cold air into the housing 13 and provide positive pressure. A movable gate (not shown in the figure) can be provided in the housing 13, which will be opened when the positioning module 10 is working.

[0022] Please refer to Figures 1 to 3. In step 204, the positioning module 10 performs positioning detection on the marked surfaces 21A to 21F of materials 20A to 20F, such as the side or end faces, and transmits the detection results to the central control system 30 for analysis. This disclosure can detect a single material 20A, or it can detect multiple materials 20A to 20F simultaneously. The following description uses only one material 20A as an example.

[0023] If the positioning module 10 is a three-dimensional vision camera with image transmission function, it can capture images of the marked surface 21A and transmit the images to the central control system 30 for analysis.

[0024] The positioning detection items include, for example, detecting the spatial coordinates and depth of the marking surface 21A, as well as detecting the tilt of the marking surface 21A and performing trapezoidal correction. Therefore, the marking problem of material 20A deforming under thermal expansion and contraction can be improved.

[0025] As shown in Figures 2 and 3, when the central control system 30 receives a majority of images, it can determine the position of the label surface 21A of the material 20A based on the image content.

[0026] Please refer to Figures 1 to 4. In step 206, the central control system 30 controls a motion module 40 to drive a cleaning module 50 to clean the marked surface 21A according to the positioning detection result.

[0027] As shown in Figure 2, the motion module 40 is, for example, a robotic arm, which may be a multi-axis motion control joint type robotic arm, having a working end 41 or a flange. The labeled module 60 is, for example, a spray gun, which can be detachably disposed at the working end 41 of the motion module 40.

[0028] The motion module 40 is electrically connected to the central control system 30, and the operation of the motion module 40 can be controlled by the central control system 30. The motion module 40 can replace human labor to perform operations in unsuitable high-temperature environments; the motion module 40 may, for example, have mobility or be installed on a mobile vehicle.

[0029] As shown in Figure 3, a protective sleeve 42 can be wrapped around the motion module 40. The protective sleeve 42 can withstand a temperature of at least 350 degrees Celsius to protect the motion module 40 from damage in high-temperature operating environments.

[0030] Please refer to Figure 3. The cleaning module 50 includes a cleaning brush that is detachably mounted on the working end 41 of the motion module 40 to clean dirt on the marking surface 21A, such as rust on the marking surface 21A.

[0031] Comparing Figure 2 and Figure 3, the spray gun 61 of the marked module 60 and the cleaning brush of the cleaning module 50 can be detachably mounted on the working end 41 of the motion module 40. That is, they can be replaced with other working tools depending on the work content.

[0032] Please refer to Figures 1, 2, and 4. In step 208, the central control system 30 controls the motion module 40 to drive the spray gun 61 of the annotation module 60 to perform annotation on the annotation surface 21A based on the positioning detection results. The annotation module 60 performs automated annotation through the control of the central control system 30, which can avoid human annotation errors.

[0033] Please refer to Figure 4. The cleaning module 50, for example, includes a pipeline assembly consisting of interconnected pipes, pumps, motors, valves, and material tanks, and is electrically connected to the central control system 30. It includes a spray gun cleaning assembly 51 and a paint stabilizing module 52. The spray gun cleaning assembly 51 further includes a water tank 513, a water pipeline 514, a water pump 515, and a directional valve 516. This disclosure does not limit the paint to be water-based or oil-based.

[0034] A water pump 515 is used to supply high-pressure clean water or solvent to the spray gun 61. A clean water tank 513 holds, for example, clean water W or solvent. A clean water line 514 connects the spray gun 61 and the clean water tank 513. The water pump 515 is connected to the clean water tank 513 via a water pump line 517, used to pump clean water W to the spray gun 61 via the clean water line 514. A directional valve 516 is located at the rear end of the suction line 512 and the clean water line 514, used to switch between clean water or paint entering the spray gun 61 according to the command of the central control system 30.

[0035] The spray gun cleaning component 51 is electrically connected to the central control system 30, and the central control system 30 controls the spray gun cleaning component 51 to provide high-pressure clean water to clean the spray gun 61 in a timely manner.

[0036] In addition, the suction motor 511 is connected to a paint pump 520 and a paint tank 521 via circulation pipes 518 and 519. The paint tank 521 contains paint P and is connected to the spray gun 61 via paint pipe 522. The paint pump 520 is connected to the paint tank 521 via paint pump pipe 523 to pump paint P to the spray gun 61 via paint pipe 522.

[0037] The suction pipe 512, suction motor 511, paint pump 520, circulation pipes 518 and 519, paint tank 521 and paint pipe 522 constitute a paint stabilizing module 52, which provides a stirring and flow effect on the paint P in the paint tank 521 (the stirring device is built into the paint tank 521) to prevent the paint P from solidifying; the paint stabilizing module 52 is also electrically connected to the central control system 30.

[0038] Thus, the cleaning module 50 is used to remove rust from the marked surface of the material 20A, while the paint stabilizing module 52 can improve the problem of nozzle blockage of the spray gun 61 or the difficulty of solidifying high-temperature paint.

[0039] Please refer to Figure 5, which shows the flowchart 200A of the automatic material labeling method disclosed herein. The main difference between the flowchart of the embodiment in Figure 5 and the flowchart of the embodiment in Figure 1 is that the flowchart of the embodiment in Figure 5 adds steps 205 and 207. Please also refer to Figures 2 to 5 to explain the steps of the flowchart 200A of the automatic material labeling method.

[0040] Step 202: The positioning module 10 detects that materials 20A~20F have entered the detection range 11.

[0041] Step 204: The positioning module 10 performs positioning detection on the marking surfaces 21A~21F of the material 20A~20F, and transmits the detection results to the central control system 30 for analysis.

[0042] Step 205: If the central control system 30 analyzes the image and determines that the distance of the material 20A is too far or exceeds the working range of the motion module 40, then abandon the labeling operation of the material 20A and trigger the alarm system 12 to issue an abnormal alarm, and continue to detect the labeling surface 21B of the next material 20B.

[0043] Similarly, if the positioning module 10 detects the marking surfaces 21A-21F of materials 20A-20F at the same time, and the central control system 30 determines that any one or more of the materials 20A-20F cannot be marked, then the problematic materials are skipped, and only the materials with normal positions and that can be marked are processed.

[0044] Step 206: Based on the positioning detection results, the central control system 30 controls the motion module 40 to drive the cleaning module 50 to clean the marked surfaces 21A~21B.

[0045] Step 207: The central control system 30 controls the spray gun cleaning component 51 of the cleaning module 50 to clean the spray gun 61, and then executes step 208.

[0046] Step 208: Based on the positioning detection results, the central control system 30 controls the motion module 40 to drive the spray gun 61 of the marking module 60 to mark on the marking surfaces 21A~21F.

[0047] After executing step 208, the process can return to step 207 as needed, whereby the central control system 30 controls the spray gun cleaning component 51 to clean the spray gun 61, and then execute step 208 again.

[0048] In summary, the automatic material labeling method disclosed herein addresses the labeling problem caused by deformation of steel billets due to thermal expansion and contraction through a positioning module; a motion module replaces manual labor in unsuitable environments; a labeling module automates labeling through a central control system, avoiding human error; a cleaning module improves labeling failures caused by paint spray guns and steel billet rust, significantly enhancing labeling accuracy and stability; and a paint stabilization module addresses the problem of high-concentration paint easily solidifying and clogging when used with high-temperature materials. The automatic material labeling method disclosed herein mitigates the risks, operational errors, and costs associated with conventional labeling procedures, significantly reducing labor costs and industrial safety risks. It also records the quantity of steel billets and process time during the process for subsequent processing and record retrieval, while preventing human labeling errors or misprinting of product production information on paper documents.

[0049] Although this disclosure has been disclosed above with reference to embodiments, it is not intended to limit this disclosure. Anyone skilled in the art can make some modifications and refinements without departing from the spirit and scope of this disclosure. Therefore, the scope of protection of this disclosure shall be determined by the appended claims. [Simplified Explanation of the Diagram]

[0013] Figure 1 is a flowchart of one embodiment of the automatic material labeling method disclosed herein. Figure 2 is a system architecture diagram of one embodiment of the automatic material labeling method disclosed herein. Figure 3 is a system architecture diagram of another embodiment of the automatic material labeling method disclosed herein. Figure 4 is a system architecture diagram of the spray gun and spray gun cleaning assembly of the automatic material labeling method disclosed herein. Figure 5 is a flowchart of another embodiment of the automatic material labeling method disclosed herein.

Claims

1. An automatic material labeling method, suitable for being established in a software program and read by a central control system to execute the following steps: (a) a positioning module detects at least one material entering a detection range; (b) the positioning module performs positioning detection on the labeling surface of the material and transmits the detection result to the central control system for analysis; (c) the central control system controls a motion module to drive a cleaning module to clean the labeling surface based on the detection result; and (d) the central control system controls the motion module to drive a spray gun of a labeling module to label the labeling surface based on the detection result, wherein, The motion module is a robotic arm with a working end, and a cleaning brush of the cleaning module and a spray gun of the labeling module are detachably mounted on the working end.

2. In the material automatic labeling method of request item 1, when performing step (b), the central control system analyzes the detection result and determines that the distance of the material is outside the working range of the motion module, then abandons the labeling operation of the material and triggers an alarm system to issue an abnormal alarm.

3. As in the material automatic labeling method of request item 1, after performing step (c), the central control system controls the cleaning module to clean the spray gun, and then performs step (d).

4. The automatic labeling method for materials as requested in item 1, wherein in performing step (a), the material is conveyed into the detection range by a conveyor belt and then stops moving, and at least one of the materials is provided on the conveyor belt.

5. The automatic material labeling method as described in Request 1, wherein the positioning detection includes detecting the spatial coordinates and depth of the labeling surface, and detecting the tilt of the labeling surface and performing trapezoidal correction.

6. The material automatic labeling method as described in Request 1, wherein the positioning module is a three-dimensional vision camera used to capture an image of the labeling surface and transmit the image to the central control system for analysis.

7. The material automatic labeling method as described in claim 1, wherein the cleaning module further includes a spray gun cleaning component and a paint stabilizing module, and a directional valve switches the connection of the spray gun cleaning component and the paint stabilizing module to the spray gun.

8. An automatic material labeling system, comprising: A central control system that internally stores and executes software programs such as request item 1. A 3D vision camera, such as the positioning module of claim 1, electrically connected to the central control system for acquiring images of multiple materials; a robotic arm, such as the motion module of claim 1, electrically connected to the central control system; and a pipeline assembly electrically connected to the central control system for connecting the spray gun and supplying paint to the spray gun.

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